Method and Apparatus for Sorting, Counting and Packaging Pharmaceutical Drugs and Other Objects

ABSTRACT

A method and apparatus is provided for handling loose objects having different physical characteristics, such as pharmaceutical drugs including, without limitation, oral solids in the form of pills, tablets, capsules and the like. Loose objects are loaded into individual canisters. A tooling assembly, comprising at least one canister drive mechanism, imaging sensor and package handler is mounted to a gantry assembly, can be translated through the cabinet via the gantry assembly to engage with particular canisters in accordance with unique and dynamic control parameters. Objects are dispensed from a canister directly to the desired packaging, such as a vial or “blister pack.” Additionally, a beneficially stronger blister pack container is provided.

CROSS REFERENCES TO RELATED APPLICATIONS

THIS APPLICATION IS A CONTINUATION OF APPLICATION SER. NO. 11/975,859,FILED OCT. 22, 2007, CURRENTLY PENDING, WHICH CLAIMS PRIORITY FROM U.S.PROVISIONAL PATENT APPLICATION SER. NO. 60/853,698, FILED OCT. 23, 2006.

STATEMENTS AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSOREDRESEARCH AND DEVELOPMENT

NONE

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention pertains to a method and apparatus for handlingloose objects having different physical characteristics. Moreparticularly still, the present invention pertains to a method andapparatus for storing, sorting, counting and packaging loose objects,such as pharmaceutical drugs including, without limitation, pills,tablets, capsules and the like. More particularly still, the presentinvention pertains to a method and apparatus for sorting, counting andpackaging pharmaceutical drugs having different physical characteristicsincluding, without limitation, sizes, shapes, textures, colors and/orweights.

2. Brief Description of the Prior Art

Modern day pharmaceutical drugs—such as pills, tablets, capsules and thelike—exhibit a wide variety of physical characteristics including, butnot necessarily limited to, sizes, geometries, textures, shapes, colorsand weights. Storing, handling, accounting for, and packaging of, suchdrugs have proven to be a challenge for the pharmaceutical distributionindustry. Although such tasks have historically been performed manually,it is widely recognized that effective automation of such tasks greatlyimproves the overall cost, efficiency and accuracy of such tasks.

Attempts have been made to automate various tasks associated with thehandling of pharmaceutical drugs. Such efforts have been reasonablysuccessful in certain limited circumstances; existing automatedpharmaceutical drug handling systems have yielded passable results whenonly a single type of drug is being handled and/or when equipment spaceis not an issue. For example, in the bulk distribution scenario,large-scale equipment can be specifically matched to a particular typeof drug, operated for an extended period, and then broken down andre-tooled before changing to a different drug.

Unfortunately, existing automated handling systems have proven to beinadequate when used to simultaneously handle multiple pharmaceuticaldrugs (that is, pills, tablets, capsules, etc.) having differentphysical characteristics, and/or when space for automated handlingequipment is limited. Such existing handling systems typically utilizeone or more of the following:

-   -   rotating slotted disks with slot dimensions matched to        particular pill dimensions;    -   rotating slotted drums with slots matched to particular pill        dimensions;    -   rotating wheels with vacuum holes and adjustable sweepers set by        the user to allow a single pill to pass at a time;    -   pressurized air to fluidize pills (similar to a lotto or bingo        machine);    -   “v-shaped” vibratory trays;    -   augers that pull pills up an incline and are jogged back and        forth at pre-determined rates matched to a particular pill        characteristics so that pills singulate as they are fed up the        incline; and    -   ribbed, rotating plates that move pills toward the outer rim of        such plates, and an adjustable sweeper to allow only one pill at        a time to be diverted from this rim to a drop-out chute.

Existing automated handling devices, including those described above,suffer from a number of very serious deficiencies. Most existingautomated systems cannot simultaneously account for multiplepharmaceutical drugs having different physical characteristics becauseautomation hardware must be matched to a specific type of drug beinghandled. At a minimum, such existing systems must be frequently (and insome cases continuously) adjusted in order to handle different drugs andobtain desired levels of accuracy. Further, accuracy of such systems hasnot proven to be reliable.

Importantly, because different drugs come in contact with certain commonelements of the handling equipment, existing pharmaceutical handlingsystems can permit cross contamination. Residue from one type of drugcan be left behind on the equipment surfaces encountered by the drugsbeing handled by such equipment. The residue can then be picked up byother drugs coming in contact with such equipment surfaces, therebyresulting in contamination of such drugs. Additionally, most existingmethods do not permit packaging of sorted and/or counted drugs, andthose that do allow packaging of drugs do not permit counting of thedrugs directly into such packaging.

Existing drug handling systems also suffer from some especially seriouslimitations during the packaging of pharmaceutical drugs, particularlywhen such drugs are packaged in sealed containers commonly referred toas “blister cards” or “blister packs.” Such existing automated drugpackaging systems frequently utilize a rotary drum or other countingsystem that dispenses the counted objects into an external shuttle orother device. The shuttle contents are then transferred into blisterpack trays. Such systems add an unnecessary step to the process betweenthe counting and packaging phases. This unnecessary step allows forcross contamination, as drug residue can collect on the shuttle and betransferred to other drugs. Such systems yield generally poor results,have large footprints and occupy an excessive amount of space.

As a result of the aforementioned limitations, existing automatedpharmaceutical handling systems are not ideally suited to serving theneeds of Long Term Care (LTC) or retail pharmacies. Such existingsystems, and particularly those that include a packaging function, areeither too expensive or too bulky (or both) for such applications. Arelatively small and inexpensive automated pharmaceutical handlingsystem would reduce the labor burden on technicians in LTC and retailpharmacies.

Thus, there is a need for an automated pharmaceutical handling methodand apparatus that can simultaneously handle multiple drugs (that is,pills, tablets, capsules, etc.) having different physicalcharacteristics. The apparatus should be relatively compact, such thatit can be used in virtually any environment including, withoutlimitation, in pharmacies or other areas where space is limited. Theapparatus should permit isolation of different drugs from one another toprevent cross contamination, and should allow for accurate and efficientsorting, counting and packaging of such drugs. The apparatus should alsopermit the counting and packaging of such drugs in a single process toimprove accuracy and eliminate cross contamination. Further, theapparatus should permit such drugs to be counted and/or dispenseddirectly into packaging (such as, for example, vials, strip sealpouches, blister pack trays or other packaging), as desired.

SUMMARY OF THE PRESENT INVENTION

The present invention comprises a method and apparatus for automatedhandling of objects having different physical characteristics, such aspharmaceutical drugs including, without limitation, pills, tablets,capsules and the like, having multiple sizes, geometries, textures,shapes, colors and/or weights. The present invention permits thesimultaneous storage, sorting and counting of multiple objects. Further,the present invention permits on-demand packaging of such objects,including the filling, sealing, and labeling of blister packs, allutilizing a single piece of equipment having minimal space and powerrequirements.

It should be noted that the present invention has a number ofadvantages, and can be beneficially utilized in a number of differentapplications. For ease of reference, the invention is discussed hereinprimarily with respect to pharmaceutical drugs, and in the context ofthe pharmaceutical distribution industry. However, the description setforth herein is for illustration purposes only, and is not intended tolimit or otherwise restrict the scope of the present invention in anyway.

Although the method and apparatus of the present invention can be usedin any number of different applications, the invention is particularlybeneficial for pharmacies serving the LTC industry and/or the retailmarket. LTC pharmacies frequently package a large percentage of theirprescriptions in a multi-dose (such as a 30-day) supply format such assealed blister packs, while retail pharmacies typically dispense theirprescriptions in vials. The present invention can fill, seal, and labelsealed blister packs, and/or dispense directly into vials, therebyrelieving a significant labor burden on pharmacy technicians.

The present invention broadly comprises a method and apparatus forstoring, sorting, metering and packaging objects such as, for example,pharmaceutical drugs in pill form. In the preferred embodiment, thepresent invention comprises at least one cabinet member having aplurality of removable canisters beneficially arrayed in a plurality ofrows and columns, a motion control system, a canister drive and controlsub-system, an imaging sub-system, a packaging sub-system, a processingsub-system and a power sub-system.

The present invention further comprises a method for positioning acanister drive mechanism, sensing apparatus and package handlerproximate to particular canisters, as desired, to address such canistersin accordance with unique and dynamic control parameters. In thepreferred embodiment of the present invention, at least one canisterdrive mechanism, imaging sensor, and package handler are disposed onend-of-arm tooling disposed on a Cartesian robot, which is in the formof an automated gantry assembly. Such components translate through thecabinet via said Cartesian robot to engage the particular canister(s)containing desired objects (pills).

Each removable canister in the cabinet comprises a container having atleast two distinct areas, one for bulk pill storage and another for pillflow control. Pills are loaded into the bulk storage area of eachremovable canister to be utilized; in most cases, only a single type ofpill is loaded into a canister at a particular time. In the preferredembodiment, each canister contains a plurality of surfaces in the bulkstorage area of said canister to permit gravity feeding of the storedpills to a metering device. The metering device, which is located nearthe lower portion of the bulk storage area, ensures a controlled flow ofpills onto a flow control ramp. Importantly, the pills contained withineach canister only come in contact with certain internal surfaces ofthat particular canister, and the contents of the different removablecanisters remain isolated from each other, thereby preventing crosscontamination of pills.

In the preferred embodiment, each canister of the present inventionfurther includes a flow control device. Said flow control devicegenerally comprises a ramp having a continuous multi-planar surface forimparting energy onto pills situated on said ramp, and facilitating thefeed forward control process of the system. Each ramp has a concavecross-section along its width and a convex planar cross-section alongits length. The concave cross-section promotes end-to-end alignment ofpills, while the convex cross-section acts to accelerate the pills indirection of flow in order to control separation of pills. Themulti-planar ramp defines a step (drop) from one section to anotheralong a substantially continuous surface, is less abusive to the pillssituated thereon compared to other handling devices, and promotessingulation and separation of such pills.

In the preferred embodiment, the ramp is vibrated to impart energy onthe pills situated on said ramp. Specifically, the ramp surface isvibrated along the longitudinal axis of said ramp, with dynamic closeloop control of the amplitude and frequency of such vibration, tocontrol orientation and flow of pills situated on said ramp.Additionally, the horizontal orientation of the longitudinal axis of theramp is dynamically adjustable (that is, the inclination or declinationof the ramp can be dynamically adjusted) so that gravitational force isused to increase or decrease pill separation and flow direction of pillssituated on said ramp.

The present invention utilizes a machine vision based imaging sensor forclosed-loop control of pill flow. Said imaging sensor permitsimplementation of feed forward control logic to react to problems inreal-time before pills are actually dispensed. Specifically, the presentinvention utilizes an area imaging object sensor to track pills atcertain critical stages as such pills transition through the apparatusincluding, without limitation, on the ramp of each canister. Informationobtained from imaging scanner is sent to at least one processor thatcontrols various elements of the present invention including, withoutlimitation, actuators that adjust ramp inclination and vibration. Sucharea imaging object sensor provides increased control and management ofthe pills throughout the handling process.

One embodiment of the imaging system of the present invention utilizes areflective imaging device capable of controlling a plurality of lightemitting devices over a range of different wavelengths. The reflectedenergy is mechanically and electronically filtered in order to track thepills. In another embodiment, the imaging system of the presentinvention comprises a translucent rear illuminated surface forsilhouetting pills in flow. The use of back lighting allows for maximumcontrast and improved pill tracking.

The present invention utilizes at least one processor to implement amethod of feed forward control logic to expedite the filling ofdifferent pharmacy packaging with a common canister and control. Withclosed loop control on all drive components associated with pill flowand packaging positing, preemptive logic improves the delivery andaccuracy of the overall filling process.

The term open loop control generally refers to systems wherein output isnot measured. Such systems are operated using consistent inputparameters without measuring whether such parameters are actuallyachieved. Such systems can become unstable thereby allowing too many, ortoo few, objects to flow. By contrast, closed loop systems (such as thesystem employed by present invention) use measured feedback todynamically adjust the input values and maintain the desired outputlevels. Closed loop systems frequently utilize an encoder tied to adrive motor, such that output can be measured and input voltage can bedynamically adjusted. Improved control allows designers to ensureconsistent operational parameters over the life of the product andacross manufactured systems.

The feed forward control processes of the present invention utilizeanticipatory logic for future events to increase the overall efficiencyand control of the system. Use of closed loop motion control with feedforward system control allows for increased accuracy and reduced cycletime by dynamically adjusting systems to account for object flow.

The present invention further comprises a novel blister card design fromfilm with sufficient stiffness so that additional laminate packaginglayers, such as cardboard sheets and the like that are frequentlyrequired to provide rigidity, are not required. An embodimentdemonstrates the effective use of an interlocking blister card toprevent the propagation of bend lines, thus allowing for the reductionof material layers. Such blister cards can be embossed with charactersformed into blisters.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description ofthe preferred embodiments, is better understood when read in conjunctionwith the appended drawings. For the purpose of illustrating theinvention, the drawings show certain preferred embodiments. It isunderstood, however, that the invention is not limited to the specificmethods and devices disclosed.

FIG. 1 depicts a front view of one embodiment of a cabinet of thepresent invention.

FIG. 1A depicts a side view of the cabinet embodiment depicted in FIG.1.

FIG. 2 depicts a front view of an alternative embodiment of a cabinet ofthe present invention.

FIG. 2A depicts a side view of the cabinet embodiment depicted in FIG.2.

FIG. 3 depicts a side perspective view of the apparatus of the presentinvention with supporting cabinet enclosure removed.

FIG. 4 depicts a side perspective view of a canister of the presentinvention.

FIG. 5 depicts a side perspective cut-away view of a canister of thepresent invention.

FIG. 6 depicts a side cut-away view of a canister of the presentinvention.

FIG. 7 depicts a perspective view of a multi-planar ramp of the presentinvention.

FIG. 8 depicts a front view of a multi-planar ramp of the presentinvention.

FIG. 9 depicts a side view of a multi-planar ramp of the presentinvention.

FIG. 10 depicts a side view of a multi-planar ramp of the presentinvention in raised and lowered positions.

FIGS. 11 through 14 depict side views of a multi-planar ramp of thepresent invention having loose objects disposed on the upper surface ofsaid ramp.

FIG. 15 depicts a side perspective view of an end-of-arm toolingassembly of the present invention engaged with a canister of the presentinvention.

FIG. 16 depicts front view of an end-of-arm tooling assembly of thepresent invention engaged with a canister of the present invention.

FIG. 17 depicts a side perspective view of an end-of-arm toolingassembly of the present invention holding a blister pack tray.

FIG. 18 depicts an end view of an end-of-arm tooling assembly of thepresent invention holding a blister pack tray.

FIG. 19 depicts a side perspective view of an end-of-arm toolingassembly of the present invention holding a vial.

FIG. 20 depicts a side cut away view of an end-of-arm tooling assemblyof the present invention holding a vial and engaged with a canister ofthe present invention.

FIG. 21 depicts an overhead view of a prior art blister pack tray.

FIG. 21A depicts a side view of the existing prior art blister pack traydepicted in FIG. 21.

FIG. 22 depicts a side view of the prior art blister pack tray depictedin FIGS. 21 and 21A exposed to bending forces.

FIG. 23 depicts an overhead view of an improved blister pack tray of thepresent invention.

FIG. 23A depicts a side view of the improved blister pack tray of thepresent invention depicted in FIG. 23.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION

The present invention has a number of advantages, and can bebeneficially utilized in a number of different applications involvingthe sorting, counting and/or packaging of loose objects. For ease ofreference, the present invention is described herein primarily inconnection with applications involving pharmaceutical drugs and othersubstances, and especially drugs and other substances delivered in theform of oral solids. The description set forth herein is forillustration purposes only, and is not intended to limit or otherwiserestrict the scope of the present invention in any way. For illustrationpurposes, the present invention is described in connection with thehandling of pills; however, it is to be observed that the presentinvention can be used with a multitude of other oral solids or looseobjects.

The present invention broadly comprises a method and apparatus forstoring, sorting, counting and packaging loose objects such as, forexample, pharmaceutical drugs in pill, tablet and/or capsule form.Referring to the drawings, FIG. 1 depicts a front view of a cabinetmember 10 of the present invention, while FIG. 1A depicts a side view ofsaid cabinet member 10. It is to be observed that the specific designparameters of said cabinet member 10 can be varied to meet particularneeds. As a result, said cabinet member 10 can be manufactured having awide range of shapes, sizes and/or configurations depending upon theintended use of the present invention, as well as the specificenvironment in which the present invention is to be utilized. Stillreferring to FIG. 1, cabinet member 10 generally comprises a pluralityof removable canisters 100 disposed within external cabinet supportframe 11. Cabinet member 10 further comprises processing/control module40 and packaging module 50. Such components are generally depicted inFIG. 1A as well, except for canisters 100 which are obscured from viewin FIG. 1A.

FIGS. 2 and 2A depict front and side views, respectively, of analternative embodiment of cabinet member 10 of the present invention.The embodiment depicted in FIGS. 2 and 2A are similar to the embodimentsdepicted in FIGS. 1 and 1A, except that cabinet member 10 has a singlearray of canisters 100, and a vertical layout of packaging module 50. Bycontrast, in the embodiment depicted in FIGS. 1 and 1A, cabinet member10 has two distinct grids of canisters 100, and a horizontal orientationof packaging module 50. In many cases, the specific layout of theindividual components of the present invention (including, but notnecessarily limited to, canisters 100, processing/control module 40 andpackaging module 50) in support frame 11 of cabinet member 10 will bedictated by a number of factors related to the specific application inwhich the apparatus will be utilized. Such factors include, withoutlimitation, the type of pills being handled, the location and/orenvironment in which said cabinet will be employed, and/or theparticular type of prescription container that an application willsupport.

In most cases, cabinet member 10 of the present invention isbeneficially tailored to best accommodate its intended use. By way ofillustration, but not limitation, when the apparatus of the presentinvention is to be utilized in an LTC or retail pharmacy setting (or anyother location where space may be limited) it is generally beneficialthat support frame 11 of said cabinet be relatively compact with a smallfootprint requiring minimal floor space.

FIG. 3 depicts a side perspective view of the apparatus of the presentinvention generally depicted in FIG. 2, external cabinet support frame11 removed. Referring to FIG. 3, removable canisters 100 arebeneficially arrayed in a grid pattern defining a plurality of rows andcolumns. Automated gantry assembly 20, which comprises a plurality ofelongate and slidably connected rails, such as vertical rail 21 andhorizontal rail 22, is powered by drive motor assembly 23 and is mountedin general proximity to one face of said canisters 100. In the preferredembodiment of the present invention, said automated gantry assembly 20comprises a Cartesian robot assembly of a type that is well known tothose having ordinary skill in the art. In the preferred embodiment,said automated gantry assembly 20 is used to position components of thepresent invention proximate to particular canisters 100, as desired, inorder to address and engage such canisters in accordance with unique anddynamic control parameters. Specifically, such components are translatedthrough cabinet member 10 within support frame 11 (not depicted in FIG.3) via automated gantry assembly 20 to engage with particularcanister(s) 100 containing desired loose objects (such as, for example,pills) to be sorted, counted and/or packaged in accordance with thepresent invention.

Still referring to FIG. 3, packaging module 50 may comprise a number ofdifferent components depending upon different application variablesincluding, without limitation, the type of packaging to be utilized in aparticular situation. However, in the preferred embodiment of thepresent invention, packaging module 50 will typically beneficiallyinclude one or more of the following components: container stock storagebin 51, sealing and labeling module 52, sealing stock storage 53 andsealed package output 54.

Still referring to FIG. 3, automated gantry assembly 20 is beneficiallyutilized to translate end-of-arm tooling assembly 300 to desiredlocations within external cabinet support frame 11 of cabinet member 10(not depicted in FIG. 3). In many applications, automated gantryassembly 20 will first translate end-of-arm tooling assembly 300 toprescription container stock storage bin 51 to retrieve an emptyprescription container. After securing an empty container, end-of armtooling assembly 300 is translated to a desired canister 100 viaautomated gantry assembly 20, and engaged with said canister fordispensing of particular pills directly into said container inaccordance with the teachings of the present invention. When dispensingoperations are completed, end-of-arm tooling assembly 300 disengagesfrom said engaged canister 100, and thereafter deposits a filledcontainer in the sealing and labeling module 52. Said filled containercan be sealed and labeled in module 52. Thereafter, the filled andsealed container is then deposited in sealed package output component 54for further handling. The aforementioned basic process can be repeatedfor each fill request.

When loose objects are packaged using blister packs, sealing andlabeling module 52 of the present invention can be utilized to performthe sealing and labeling operations of the present invention. In mostcases, blister packs comprise a molded film tray having a plurality ofspaced indentions. Pills are deposited within such indentions of suchfilm tray containers as more fully set forth herein. Thereafter,automated gantry assembly 20 translates said filled tray to said sealingand labeling module 52. In most cases, a foil cover is thereafter placedover and secured to said film tray, and secured using a cold sealadhesive to enclose said pills within the filled blister pack tray.Frequently, a roller is also used to apply pressure to said foil coverto ensure proper adhesion of such foil to said film tray container.After the foil cover is applied, a prescription label containingrequired information can be printed and placed onto the sealed blisterpack. Thereafter, said automated gantry assembly 200 can be used totransfer said sealed and labeled blister pack to sealed package outputcomponent 54 for further handling.

In the preferred embodiment, end-of-arm tooling assembly 300 of thepresent invention comprises a plurality of components. Referring brieflyto FIG. 19, such components may include at least one of each of thefollowing: at least one actuator 310, at least one light source 320,imaging sensor assembly 330, drive links 340, and prescription containerholder 350.

Referring to FIG. 3, each removable canister 100 in cabinet member 10generally comprises a separate storage container for the segregatedstorage of loose objects. Each container 100 comprises at least twodistinct regions: one region for bulk pill storage and another regionfor pill flow control. Pills are loaded into the bulk storage region ofeach removable canister 100 to be utilized; in most cases, only a singletype of pill is loaded into a particular canister at a particular time.

FIG. 4 depicts a side perspective view of canister 100 of the presentinvention. Canister 100 generally comprises canister housing 101 havingloading opening 120. Canister housing 101 acts to protect pillscontained within said canister 100 from unauthorized removal, moisture,ultraviolet penetration, and/or other contamination or spoilage. Pillscan be loaded into canister 100 through opening 120, which is equippedwith replenishment door 102. Replenishment door 102 is slidably mountedto canister housing 101, and can be beneficially locked to canisterhousing 101 for prevention of unauthorized entry into canister 100.Replenishment door 102 can also form a pressure seal against canisterhousing 101 to prevent air exchange. In the preferred embodiment of thepresent invention, replenishment door 102 is situated on the uppersurface of canister housing 101 and maintains a substantially “flush”profile with the upper surface of said canister housing 101.Importantly, pills contained within a particular canister 100 onlycontact certain internal surfaces of that particular canister, while thecontents of the other canisters remain completely isolated from suchpills. As a result, pills or pill residue from one canister do notcontact contents of another canister. The design of the presentinvention serves to prevent cross contamination of contents whendifferent substances (such as, for example, multiple types of differentdrugs) are simultaneously stored and/or handled by said invention.

Still referring to FIG. 4, canister 100 also includes external drivesockets 111, optional label surface 113 and light pipe interfaces 322.Canister 100 further comprises opening 121 for the dispensing of looseobjects from said canister. Multi-planar ramp, which is described indetail below, is disposed within canister housing 101. In the preferredembodiment, front end 204 of multi-planar ramp 200 (defining drip-offpoint 203, described below) is disposed in close proximity to opening121 in canister housing 101.

FIG. 5 depicts a perspective cut-away view of canister 100 of thepresent invention. In the preferred embodiment, each canister 100contains a plurality of cooperating components and surfaces situatedwithin canister housing 101 that facilitate gravity feeding of looseobjects (such as pills) stored within each such canister 100. Stillreferring to FIG.5, pills loaded within canister housing 101 throughopening 120 are permitted to migrate along inclined upper baffle 103.Said pills travel from upper baffle 103 to inclined lower baffle 104,and thereafter onto bulk metering ramp 105. When canister 100 is engagedby end-of-arm tooling assembly 300, energy can be supplied to canister100 to vibrate upper baffle 103 and lower baffle 104. Baffle link 110connects upper baffle 103 to lower baffle 104, and serves to transfersuch vibratory energy between said upper and lower baffles. After pillswithin canister 100 reach bulk meter ramp 105, flow of such pills isbeneficially controlled by bulk meter gate 106. Bulk meter gate 106permits a controlled number of pills onto ramp 200, thus preventing anover-supply of pills on ramp 200.

Bulk meter gate 106 ensures a controlled flow of pills onto ramp 200.Pill motion on ramp 200 is observed by an imaging sensor assemblydisposed on end-of-arm tooling assembly 300 (not shown in FIG. 5). Inthe preferred embodiment, said imaging sensor utilizes machine vision toaccount for objects in the imaging area. The imaging sensor monitors theresults of actuating bulk meter gate 106, allowing closed loop controlof such actuation. The use of said imaging sensor assembly, adjustablemulti-planar ramp 200, and a closed loop feed forward control logicfurther permit the controlled flow of pills situated on the uppersurface of said ramp 200.

In the preferred embodiment, ramp 200 has a continuous multi-planarupper surface to impart energy onto pills situated on said ramp 200, andto facilitate the feed forward control logic of the system. Ramp 200generally has a substantially concave cross-section across its width anda substantially convex planar cross-section across its length. Theconcave cross-section promotes end-to-end alignment of pills on theupper surface of said ramp, while said convex cross-section acts toaccelerate the pills in a desired direction in order to controlseparation of pills. The multi-planar surface of ramp 200 defines a step(drop) from one section to another section along a continuous surface,is less abusive to the pills situated on said ramp compared to otherhandling devices, and promotes singulation and separation of pills onsaid ramp 200.

FIG. 6 depicts a side cut away view of canister 100 of the presentinvention. Referring to FIG.6, inclined upper baffle 103 is pivotallyconnected to the inner surface of canister housing 101 using upper pivotpin 107. Similarly, inclined lower baffle 104 is pivotally connected tothe inner surface of canister housing 101 using lower pivot pin 108.Baffle link 110 connects upper baffle 103 to lower baffle 104. In thepreferred embodiment, bulk metering ramp 105 has inclined upper surface105 a defining a pitch that is oriented perpendicular to thelongitudinal axis of said ramp. Said bulk metering ramp 105 is furtherpivotally attached to the inner surface of canister 101 using meteringpivot pin 109. Bulk meter gate 106 is connected to the distal end oflower baffle 104 (opposite lower pivot pin 108) via slotted mountingbracket 112, and limits the flow of pills onto ramp 200. Ramp 200 ispivotally mounted to canister housing 101 at forward end 205, and pivotsabout a horizontal axis oriented perpendicular to the longitudinal axisof ramp 200. End 205 of ramp 200 is not mounted, and is free to travelalong an arc, thereby permitting the incline angle of ramp 200 to beadjustable.

Referring to FIG. 7, ramp 200 has forward end 204 and free end 205. Ramp200 further has a substantially concave cross sectional profile acrossits width, and a substantially convex cross sectional profile along itslongitudinal axis. Across its width, cross section of ramp 200 forms acontinuous concave surface (in the preferred embodiment, using aplurality of intersecting planes) for promoting flow of pills toward thelower portion of said cross section. Said cross section can be in theform of a two-plane (“V-shape”) cross section, or other effective shape,such as a smooth and continuously curved concave parabola. When mountedwithin a canister 100, ramp 200 pivots near end 204 about a rotationalaxis passing through cylindrical mounting pins 210. Referring to FIG. 8,which depicts a front view of multi-planar ramp 200, the longitudinalaxis of ramp 200 comprises a plurality of inclined surfaces arrayed toform a continuous, but substantially convex, upper surface. Generally,the angular difference between the different inclined surfaces of ramp200 permit the control system of the present invention to effectivelymanage pill separation and velocity (speed and direction) throughdynamic adjustment of the incline of ramp 200.

FIG. 9 depicts a side view of multi-planar ramp having front end 204 andfree end 205. In the preferred embodiment, ramp 200 of the presentinvention comprises a plurality of distinct zones. Zone A is situated atthe leading edge of ramp 200 nearest drop-off point 203, which permitscontrol of pill trajectory as pills depart ramp 200. Zone A of ramp 200has beneficial profile 201, such that the exit angle of said rampremains substantially consistent over the rotational limits of ramp 200as said ramp pivots about cylindrical mounting pins 210. FIG. 10, whichdepicts a comparison view of ramp 200 in both raised and loweredpositions, illustrates how the profile of ramp 200 can minimize thetrajectory migration of pills depending upon the incline angle of saidramp 200. For purposes of the discussion, trajectory migrationrepresents the difference between raised ramp trajectory and a loweredramp trajectory for a given drop height, where said drop height isdefined as the distance from drop-off point 203 at end 204 of ramp 200,to the top of a receiving container held by end-of-arm tooling assembly300.

Referring back to FIG.9, multi-planar upper surface of ramp 200 furtherdefines Zone B, Zone C and Zone D. In the preferred embodiment, saidzones have linear cross sections with a decreasing surface anglerelative to level reference “x”. Thus, Angle B is greater than Angle C,which is in turn greater than Angle D. Using such a decreasingrelationship of zone angles, the control system of the present inventioncan effectively manage flow of loose objects, such as pills.

FIGS. 11 through 14 illustrate pills 1 and 2 moving in train towarddrop-off point 203 at forward end of ramp 200. Referring to FIG. 11,pill 1 accelerates at a different rate than pill 2 due to the surfaceangle difference on ramp 200. Referring to FIG. 12, both pill 1 and pill2 are situated in the same zone along the upper surface of ramp 200(Zone C shown on FIG. 9) and accelerating at the same rate; however, thevelocity of pill 1 is greater than the velocity of pill 2 due to theincreased time at Zone C's acceleration. Spacing between pill 1 and pill2 is tracked along ramp 200, and when the minimum required spacing ismaintained, the orientation of ramp 200 is not adjusted. However, whenminimum required spacing between pill 1 and pill 2 is not maintained,corrective action is implemented by dynamic adjustment to theinclination of ramp 200. As FIG. 13 illustrates, ramp 200 can beoriented so that pill 1 travels in one flow direction, while pill 2travels in the opposite flow direction. Once minimum spacing betweenpills 1 and 2 is obtained and observed, orientation of ramp 200 isreturned to the position depicted in FIG. 14, thereby allowing both pill1 and 2 to beneficially travel in the desired flow direction. Thepresent invention also uses application of vibratory energy to ramp 200along the longitudinal axis of said ramp to promote the desired flow ofpills along the upper surface of said ramp.

In the preferred embodiment, ramp 200 is vibrated to impart energy onthe objects situated on the upper surface of said ramp. Specifically,the ramp surface is vibrated along the longitudinal axis of said ramp,with dynamic close loop control of the amplitude and/or frequency ofsuch vibration, to control orientation and flow of objects situated onsaid ramp 200. Additionally, the inclination of ramp 200 is dynamicallyadjustable so that gravitational force can be used to increase ordecrease separation and flow direction of objects situated on said ramp.

The present invention utilizes a machine vision-based imaging sensor forclosed-loop control of pill flow including, without limitation, flow ofpills situated on the upper surface of ramp 200. Said imaging sensor isused to gather information regarding pill placement. Such information isconveyed to a computer processor, which in turn implements feed forwardcontrol logic to react to problems in real-time before pills areactually dispensed from a canister 100. With closed loop control on alldrive components associated with pill flow and packaging, preemptivelogic improves the delivery and accuracy of the overall handlingprocess.

One embodiment of the imaging system of the present invention utilizes areflective imaging device capable of controlling a plurality of lightemitting devices over a range of different wavelengths. The reflectedenergy is mechanically and electronically filtered in order to trackobjects. In another embodiment, the imaging system of the presentinvention comprises a translucent rear illuminated surface forsilhouetting objects in flow. The use of back lighting allows formaximum contrast and improved object tracking.

FIG. 15 depicts a perspective view of the components of end-of-armtooling assembly 300 engaged with canister 100. In the preferredembodiment, actuators 310, light source 320, imaging sensor assembly330, drive links 340 and container holder 350 (not shown) are disposedon the end-of-arm tooling assembly 300. Said end-of-arm tooling assembly300 is translated proximate to a particular canister (containing adesired type of pills) using a gantry assembly as described above.

Referring to FIG. 15, end-of-arm tooling assembly 300 engages with acanister 100. Light source 320 directs light into light pipe 321(depicted in FIG. 6) via light pipe interfaces (depicted in FIG. 4),thereby permitting transmission of light into canister 100. Such lightfrom light source 320 permits illumination of ramp 200 with differentlight wavelengths. By way of example, but not limitation, suchwavelengths can include white light at approximately 5500K, red light atapproximately 630 nm, blue light at 470 nm, green light at approximately525 nm and infrared at approximately 940 nm. The ability to dynamicallychange light wavelength allows the present invention to utilize thewavelength best suited for imaging the particular objects (pills)handled by the present invention.

Sensor assembly 330 electronically and mechanically filters incominglight to determine the optimum setting for tracking pills as said pillsflow along the upper surface of ramp 200. In order to manage pill flow,the processing system of the present invention utilizes informationobtained from sensor assembly 330 to compute the size and position ofpills on ramp 200, confirm or deny pill placement and, if necessary,take corrective action. Frequently, such corrective action comprisestransfer of mechanical energy to canister 100 by actuators 310 disposedon end-of-arm tooling assembly 300. Energy is transferred from saidactuators 310 to canister 100 and its various components using actuatordrive arms 311, which are connected to drive links 340. Said drive links340 engage drive sockets 111 of canister 100 (depicted in FIGS. 4 and 5)to transfer mechanical energy to the components of canister 100including, without limitation, ramp 200.

FIG. 16 depicts front view of an end-of-arm tooling assembly of thepresent invention engaged with a canister of the present invention.Input ports 312 are provided on actuators 310, and allow data transferfrom to said actuators to facilitate the feed forward control logic ofthe present invention. Actuator drive arms 311 mate with drive links totransmit energy to the components of canister 100.

FIG. 17 depicts a side perspective view of an end-of-arm toolingassembly 300 of the present invention holding a blister pack tray 400having a plurality of indentions 401 in packaging holder 350. End-of-armtooling assembly 300 has optional handle 360. FIG. 18 depicts an endview of said end-of-arm tooling assembly of the present inventionholding blister pack tray 400.

FIG. 19 depicts a side perspective view of an alternative embodiment ofend-of-arm tooling assembly of the present invention holding vial 500 invial holder 351. FIG. 20 depicts a side cut away view of an end-of-armtooling assembly 300 holding vial 500 in vial holder 351, and engagedwith canister 100 of the present invention.

As the loose objects (such as pills) flow through the region of intereston the upper surface of ramp 200, the contrast between such objects andthe background allows the sensor to define object cross-section, andtrack each object. Reliability is improved when a color spectrumcomparison and relative size comparison is conducted. In order toovercome reflectivity issues, the imaging sensor allows for the range ofthe color spectrum (visible and non-visible) to be used without hardwarereplacement. Varying the light source intensity and spectrum as neededallows the imaging sensor of the present invention to tune each countingsequence to the optimal conditions, improving effectiveness andenhancing object delivery.

A normal variant of reflective imaging is to back light the region ofinterest to produce an increased contrast, thus allowing for a lessexpensive imaging sensor to be deployed. Placing a light source behindthe region of interest allows light to reach the imaging sensor of thepresent invention with full intensity. Such light is blocked when anobject travels through the area of interest, thus allowing the imagesensor the ability to define the object's cross-section and track.

A significant advantage of the present invention is found in the designof canister 100 and the means by which pills are controlled and counteddirectly from canister 100 into a prescription container (such as, forexample, a blister pack or conventional vial) without any additionalstep or device for temporary storage of such pills.

FIG. 21 depicts an overhead view of a prior art blister pack tray, whileFIG. 21 A depicts a side view of the existing prior art blister packtray depicted in FIG. 21. Existing prior art blister packaging typicallycomprises a film container base or tray 410 having a plurality ofindentions or “blisters” 411 for receiving pills or other loose objects.Such conventional indentions are frequently arrayed in rows and columns.Frequently, such film containers lack desired stiffness or rigidity, andare susceptible to bending forces as depicted in FIG. 22, particularlyin the regions between such rows and columns. As a result, prior artblister packs are frequently packaged in a cardboard clamshell or othersimilar device to stiffen the packaging while protecting the relativelyfrail film and foil.

FIG. 23 depicts an overhead view of an alternative blister tray 400 ofthe present invention having interlocking indentations or blisters 401to increase stiffness while not compromising the sealing web. FIG. 23Adepicts a side view of the blister design illustrated in FIG. 23. Thealternative interlocking blister design of the present inventioneliminates unsupported bend lines, resulting in a reduction of filmdeflection and an increase in overall rigidity of blister tray 400.

Blister tray 400 depicted in FIGS. 23 and 23A allows a single film layerto be constructed in a manner that increases the overall packing volumeof pills (or other packaged loose objects) by arraying blisters in aninterlocking pattern. The pattern layout ensures seal width ismaintained for all blisters by decreasing wasted seal space betweenindentations. Such minimization of wasted seal space allows for a largercross section to be obtained for each blister, thus supporting lagerobjects, or an increased number of objects in each blister. Additionallythe interlocking pattern stiffens the film container by preventing bendline propagation between blisters.

The above-described invention has a number of particular features thatshould preferably be employed in combination, although each is usefulseparately without departure from the scope of the invention. While thepreferred embodiment of the present invention is shown and describedherein, it will be understood that the invention may be embodiedotherwise than herein specifically illustrated or described, and thatcertain changes in form and arrangement of parts and the specific mannerof practicing the invention may be made within the underlying idea orprinciples of the invention.

What is claimed:
 1. An apparatus for dispensing loose objectscomprising: a) a support frame; b) a plurality of canisters adapted tohold loose objects disposed within said support frame; c) a gantryassembly; d) a dispensing assembly movably disposed on said gantryassembly; and e) a processor adapted to selectively position saiddispensing assembly adjacent to at least one canister and dispense looseobjects from said at least one canister.
 2. The apparatus of claim 1,wherein said plurality of canisters is in a grid pattern.
 3. Theapparatus of claim 1, wherein each of said canisters further comprises:a) a ramp having a first end and a second end, wherein said ramp ispivotally connected to said canister and pivots about a horizontal axis;and b) at least one motor for selectively raising and lowering saidsecond end of said ramp.
 4. The apparatus of claim 3, wherein aplurality of loose objects are deposited from a canister on a ramp. 5.The apparatus of claim 4 wherein said processor measures spacing betweensaid loose objects to track said objects along the length of said rampand adjusts the position of said ramp to separate said loose objectsfrom each other on said ramp when the spacing between said objects isless than a preset minimum value.
 6. The apparatus of claim 5, whereinsaid separated loose objects are deposited directly from said surfaceinto packaging without said loose objects contacting any interveningsurface.
 7. The apparatus of claim 1, wherein said dispensing assemblyfurther comprises at least one packaging holder.
 8. The apparatus ofclaim 1, wherein said dispensing assembly comprises at least one opticalsensor.
 9. An apparatus for dispensing loose objects comprising: a) aplurality of canisters, each of said canisters comprising: i. a housinghaving an opening; ii. a ramp, having a first end, a second end, anupper surface and a longitudinal axis, wherein said ramp is mounted tosaid housing, and said first end is proximate to said opening and pivotsabout a substantially horizontal axis; and iii. a linkage assemblyconnected to said ramp; b) a motorized rail assembly; c) a dispensingassembly, movably disposed on said motorized rail assembly, comprising:i. at least one actuator; ii. at least one drive link connected to saidat least one actuator; iii. at least one sensor; and iv. at least onepackaging holder; d) at least one processor for positioning saiddispensing assembly adjacent to selected canisters and dispensing looseobjects from said canisters directly into packaging held by said atleast one packaging holder.
 10. The apparatus of claim 9, wherein saidcanisters are disposed in a grid pattern.
 11. The apparatus of claim 9,wherein the upper surface of said ramp defines a plurality of planesalong the longitudinal axis of said ramp.
 12. The apparatus of claim 9,wherein the upper surface of said ramp defines at least two pairs ofadjacent planes along the longitudinal axis of said ramp, with an anglebeing formed between each pair of adjacent planes.
 13. The apparatus ofclaim 12, wherein the angles formed between each pair of adjacent planesdecrease in the direction of said first end of said ramp.
 14. Theapparatus of claim 9, wherein the upper surface of said ramp has aconcave shape extending substantially along the entire longitudinal axisof said ramp.
 15. The apparatus of claim 9, wherein said at least onesensor comprises at least one optical scanner.
 16. The apparatus ofclaim 15, wherein said at least one optical scanner is directed at theupper surface of said ramp.
 17. The apparatus of claim 16, wherein saidat least one optical scanner is an area-wide scanner directed atsubstantially the entire upper surface of said ramp.
 18. The apparatusof claim 9, wherein said at least one sensor comprises a machine visionsystem having a field of view.
 19. The apparatus of claim 18, whereinsaid field of view comprises substantially the entire upper surface ofsaid ramp.
 20. The apparatus of claim 19, wherein said field of viewcomprises at least a portion of said packaging.
 21. An apparatus fordispensing loose objects comprising: a) at least one canistercomprising: i. a housing having an opening; ii. a ramp, having a firstend, a second end, a length and an upper surface, wherein said ramp isdisposed within said housing, and said first end is proximate to saidopening and pivots about a horizontal axis; and iii. a linkage assemblyconnected to said ramp; b) a dispensing assembly comprising: i. at leastone actuator; ii. at least one drive link connected to said at least oneactuator; iii. at least one sensor; and iv. at least one packagingholder; and c) at least one processor for dispensing loose objects fromsaid canisters directly into packaging held by said at least onepackaging holder.
 22. The apparatus of claim 21, wherein the uppersurface of said ramp defines a plurality of planes along thelongitudinal axis of said ramp.
 23. The apparatus of claim 21, whereinthe upper surface of said ramp defines at least two pairs of adjacentplanes along the longitudinal axis of said ramp, with an angle beingformed between each pair of adjacent planes.
 24. The apparatus of claim23, wherein the angles formed between each pair of adjacent planesdecrease in the direction of said first end of said ramp.
 25. Theapparatus of claim 24, wherein the upper surface of said ramp has aconcave shape extending substantially along the entire length of saidramp.
 26. The apparatus of claim 21, wherein said at least one sensorcomprises at least one optical scanner.
 27. The apparatus of claim 26,wherein said at least one optical scanner is directed at the uppersurface of said ramp.
 28. The apparatus of claim 27, wherein said atleast one optical scanner is an area-wide scanner directed atsubstantially the entire upper surface of said ramp.
 29. The apparatusof claim 21, wherein said at least one sensor comprises a machine visionsystem having a field of view.
 30. The apparatus of claim 29, whereinsaid field of view comprises substantially the entire upper surface ofsaid ramp.
 31. The apparatus of claim 29, wherein said field of viewcomprises at least a portion of said packaging.